Get More From Your Machining: Mapal PCD Tooling

by Bernard Martin

When you're cutting non-ferrous materials or composite stacks, you know that tool life, edge life, and surface finish can make or break a job. That’s where Mapal PCD tooling really shines. Known for precision, longevity, and optimized performance in high-speed applications, Mapal ’s polycrystalline diamond (PCD) solutions are engineered for shops that can’t afford to cut corners—or stop production for frequent tool changes.

Whether you're machining aluminum components for aerospace, carbon-reinforced plastics for automotive, or copper alloys for energy systems, Mapal delivers tools that stay sharp and consistent.

Why PCD?
PCD (Polycrystalline Diamond) is sintered diamond grit bonded with a metallic matrix, creating an ultra-hard cutting material ideal for abrasive and non-ferrous workpieces.

Compared to carbide, PCD offers up to 100x longer tool life in the right application—and dramatically reduces built-up edge and microburr formation, which saves time on post-processing.

Mapal’s PCD Tooling Range
Mapal offers a comprehensive selection of PCD tooling to suit everything from drilling and reaming to milling and contouring. Here's what you can expect:

PCD Milling Tools

• Applications: Face milling, slotting, shoulder milling, and contour milling of aluminum alloys, magnesium, and CFRP/GFRP.
• Sizes: Diameter ranges from Ø3 mm up to Ø200 mm depending on tool style.
• Designs: Monoblock, brazed, and replaceable-head versions.
• Tolerance: Down to ±0.01 mm on diameter, and exceptionally high surface finish capability (Ra < 0.4 µm with optimized parameters).
  

PCD Drills

• Applications: Precision drilling in aluminum engine blocks, transmission housings, and battery components.
• Geometry: Special flute geometries for optimized chip evacuation and reduced built-up edge.
• Diameter Range: From Ø3 mm up to Ø32 mm standard, with custom options available.
• Coolant Options: Internal through-coolant options for high-volume chip control.

PCD Reamers

• Applications: High-precision hole sizing in aerospace and automotive components.
• Tolerances: H6 and tighter, ensuring precise fits in critical assemblies.
• Designs: Fixed blade and adjustable reamers, with step reaming options for multi-diameter holes.

PCD Combination Tools

• For multi-step operations in a single pass—ideal for automated production lines where cycle time is critical.
• Custom-engineered based on your component specs, material, and machine interface.

Coatings and Edge Treatments
While PCD is itself the cutting edge, Mapal adds proprietary treatments to improve chip flow, reduce friction, and prevent delamination when working with layered composites. Edges can be honed or laser-cut for ultimate sharpness and consistency.

Reconditioning & Regrinding
One of the benefits of Mapal's PCD tooling is that many tools can be professionally reconditioned multiple timeswithout sacrificing performance. This significantly extends your ROI and keeps your tooling inventory lean.

Ready to Upgrade Your Tooling?
If you're cutting aluminum, magnesium, CFRP, or other non-ferrous materials, Mapals PCD tooling might be the last upgrade you need for a long while. Factory Tooling Solutions can help you spec out the right geometry, holder style, and chipbreaker for your application—and even set you up with a test tool to see the difference in action.

Let’s talk about how PCD can eliminate headaches and boost your output.

Contact FTS

Eeditors note: Jan 21, 2025  We thought you might enjoy seeing this video tour and overview of PCD tooling from Mapal from the folks at MTD CNC